Friction material and production method of friction material

ABSTRACT

A friction material including: an amorphous resin that has a chain-like polymer structure; and other components that constitute the friction material and that are components other than the amorphous resin, wherein dispersion treatment is preliminarily carried out in which the amorphous resin is dispersed in at least one of the other components, and a manufacturing method of the friction material.

INCORPORATION BY REFERENCE

The disclosure of Japanese Patent Application No, 2008-264005 filed onOct. 10, 2008 including the specification, drawings and abstract isincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a friction material, which inhibits noise andvibrations during friction, and which improves moldability and reducescosts, and a production method of such a friction material.

2. Description of the Related Art

The brake pads, brake linings, clutch facings and other frictionmaterials used in industrial machinery, railroad cars, cargo vehicles,automobiles and the like are required to have high reliability andincreasingly high performance in order to ensure safety. Morespecifically, since friction materials are responsible for convertingkinetic energy to heat through friction, they are required to have heatresistance against frictional heat generated during braking. At the sametime, from the viewpoint of running stability, they are also required todemonstrate frictional properties that remain constant regardless oftemperature or weather conditions, have superior wear resistance withlittle changes in properties over long period of time, and not generatenoise such as squealing during braking or vehicle vibrations. Inparticular, noise and vibrations attributable to frictional vibration ofthe friction material are considered to be an important technical issuefrom the viewpoint of product value and quietness of vehicles.

In order to satisfy these requirements, friction materials are formed bycombining several types of components. For example, fiber base materialsfor retaining the shape of the friction material, binders that bindcomponents such as fiber base materials, and fillers for adjustingvarious properties of friction materials (such as adjustment andstabilization of wear resistance, heat resistance or frictioncoefficient) are used in combination. Friction materials are produced bycuring a raw material mixture, which is obtained by mixing thesecomponents with a mixer, by hot-pressing followed by molding, grindingas necessary and sizing. Thermosetting resins as exemplified by phenolresins are frequently used as binders that compose friction materialsdue to their superior properties such as heat resistance, mechanicalproperties, low price and molding processability. Phenol resins are alsosubjected to modification, for the purpose of improving the propertiesand performance mentioned above. However, adequate effects have yet tobe obtained for heat resistance and frictional properties. Conventionalphenol resins are decomposed by heat during friction or be melted bythat heat, thereby having a detrimental effect on noise properties andvibration properties of friction materials. Although improvement ofvibration absorption of friction materials and inhibition of theoccurrence of squealing and other abnormal noise have been carried outby using modified phenol resin capable of lowering the hardness offriction materials, this conversely resulted in the problems of loweringthe heat resistance of friction materials and reducing moldabilityduring friction material production.

Therefore, a polyimide resin having superior heat resistance has beenproposed for use as a binder (for example, Japanese Patent PublicationNo. 5-62916). This Japanese Patent Publication No. 5-62916 describes apolyimide-based friction material obtained by thermocompression moldinga polyimide composition obtained by adding 5 to 30 parts by weight of afluororesin powder and 1 to 30 parts by weight of a transition metalpowder having unpaired electrons in the d orbital and/or an oxide powderof that transition metal to 100 parts by weight of an aromatic polyimideresin powder. In this Japanese Patent Publication No. 5-62916, afterdry-mixing each raw material at the blending ratios indicated above witha Henschel mixer, the mixture is compression molded under conditions of320 to 370° C. and 800 to 1500 kg/cm² to produce a polyimide-basedfriction material. In the examples of this Japanese Patent PublicationNo. 5-62916, a polyimide friction material is actually produced thatcontains 71 to 89% by weight of polyimide resin.

However, this polyimide resin has the disadvantages of (1) being moreexpensive than phenol resin resulting in increased cost of thefrictional material, and (2) requiring a large-scale and expensiveproduction system as a result of having to be molded at high temperatureand high pressure, thereby resulting in poor moldability andproductivity. In addition, as in the friction material described inJapanese Patent Publication No. 5-62916, using a large amount ofthermoplastic polyimide resins have the risk of (3) undergoing softeningand melting due to frictional heat during braking, thereby causingphenomena such as fading and causing a decrease in the frictionalproperties of the friction material.

SUMMARY OF THE INVENTION

As a result of conducting extensive studies, the inventors found that byusing an amorphous resin having a chain-like polymer structure as aconstituent of a friction material, the capability of the frictionmaterial to follow the surface of the counterpart material at the pointwhere frictional force is generated, namely spring property, can beimproved, and noise and vibrations during friction can be inhibited. Theinventors also found that in order to obtain effects that improve noiseproperties and vibration properties attributable to the amorphous resindescribed above while ensuring moldability, cost effectiveness andfrictional properties of the friction material, it is important toarrange the amorphous resin in a highly dispersed state in othercomponents and reduce the amount used instead of simply mixing a largeamount of binder in the form of polyimide resin with other componentsthat compose the friction material followed by molding as described inJapanese Patent Publication No. 5-62916.

The invention provides a friction material, which improves noiseproperties and vibration properties of the friction material whileensuring moldability, cost effectiveness and frictional properties, anda production method thereof.

A first aspect of the invention is a friction material, including: anamorphous resin having a chain-like polymer structure; and othercomponents that configure the friction material and that are componentsother than the amorphous resin, wherein dispersion treatment ispreliminarily carried out in which the amorphous resin is dispersed inat least one of component from among the other components.

Since the friction material of the first aspect includes an amorphousresin having a chain-like polymer structure, it has superior springproperties and is able to inhibit noise and vibrations during friction.In addition, as a result of preliminarily carrying out dispersiontreatment on the amorphous resin and at least one of constituent otherthan the amorphous resin (other component), the amount of the amorphousresin used is reduced. As a result, superior noise properties andvibration properties can be realized while ensuring moldability, costeffectiveness and frictional properties of the friction material.

An example of the amorphous resin is at least one selected from thegroup consisting of polyimide, polyamidoimide, polycarbonate,polyphenylene ether, polyarylate, polysulfone and polyether sulfone. Thecontent of the amorphous resin in the friction material is preferably0.001 to 50 vol %.

An example of the dispersed state of the amorphous resin and the othercomponents is a state in which the other components are coated with theamorphous resin. In the case a high friction component is included inthe other components and at least the high friction component is coatedwith the amorphous resin in particular, noise properties and vibrationproperties of the friction material can be effectively improved. Acomponent having a Mohs hardness of 6 or more may be used for the highfriction component. In addition, an example in which the high frictioncomponent coated with the amorphous resin is further compounded with afibrous component is able to inhibit separation of the high frictioncomponent from the surface of the friction material, thereby making itpossible to stabilize frictional properties of the friction material.

Another example of a dispersed form of the amorphous resin and the othercomponents is a state in which all other components that constitute thefriction material, other than the amorphous resin, axe coated with theamorphous resin. In the case of coating all other components with theamorphous resin, the effect of improving spring properties of thefriction material is enhanced, thereby further inhibiting the generationof noise and vibrations.

In addition, in the case of including a thermosetting resin as the othercomponents, the thermosetting resin and a powder of the amorphous resinare dispersion mixed in the above-mentioned dispersion treatment. Inthis case, the amorphous resin can be dispersed in the gaps betweenother components together with the thermosetting resin without impairingthe fluidity of the thermosetting resin during mixing and molding of thefriction material raw materials. Examples of the thermosetting resininclude at least one selected from phenolic resin, modified phenolresin, urea resin, melamine resin, benzoguanamine resin, amino resin,furan resin, unsaturated polyester resin, diallyl phthalate resin, allylresin, alkyd resin, epoxy resin, thermosetting polyamidoimide resin,thermosetting polyimide resin and silicone resin. The amorphous resinpowder may be spherical or flat and have a mean diameter of 1 μm orless. In addition, flat amorphous resin powder may have a thickness of 1μm or less and a flat shape in which the length of one side of a square,whose area is same as a surface area in the planar direction of theamorphous resin powder, is 3 μm or less.

In the case of including a thermosetting resin as the other components,an example of another dispersed state of the amorphous resin and thethermosetting resin is polymerization of the amorphous resin and thethermosetting resin.

Moreover, an example of another dispersed arrangement of the amorphousresin and the other components is an example in which the othercomponents are filled into pores of a porous body formed by theamorphous resin. An example in which sheets of the porous body are usedand the porous body sheets are laminated in a plurality of layers can beused when a plurality of porous bodies filled with the other componentsare used in a friction material. In addition, different other componentscan also be filled into at least two of the porous bodies among theplurality of porous bodies. The porous body may also function as a basematerial component that retains the shape of the friction material.

A second aspect of the invention is a production method of a frictionmaterial, including: carrying out dispersion treatment in which anamorphous resin having a chain-like polymer structure is dispersed in atleast one of other components that constitute the friction material andthat are other than the amorphous resin.

Examples of the amorphous resin include at least one selected frompolyimide, polyamidoimide, polycarbonate, polyphenylene ether,polyarylate, polysulfone and polyester sulfones. The content of theamorphous resin may be 0.001 to 50 vol %.

An example of dispersion treatment of the amorphous resin and the othercomponents is treatment in which the other components are coated withthe amorphous resin. Specific examples of coating treatment include amethod in which the other components are coated with the amorphous resinin a fluid state, and a method in which the other components are coatedwith the amorphous resin in a non-fluid state.

In addition, in the case of including a high friction component as theother components, the noise properties and vibration properties of thefriction material can be effectively improved by coating at least thehigh friction component with the amorphous resin in the above-mentioneddispersion treatment. A component having a Mohs hardness of 6 or moremay be used for the high friction component. In addition, by compoundingthe high friction component coated with the amorphous resin with afibrous component, separation of the high friction component from thesurface of the friction material can be inhibited, thereby allowing theobtaining of a friction material that demonstrates stable frictionalproperties.

Another example of dispersion treatment is treatment in which all othercomponents that constitute the friction material, other than theamorphous resin, are coated with the amorphous resin.

In addition, an example of dispersion treatment in the case of using athermosetting resin as the other components is a method in which thethermosetting resin and a powder of the amorphous resin are dispersionmixed. Examples of the thermosetting resin include at least one selectedfrom phenolic resin, modified phenol resin, urea resin, melamine resin,benzoguanamine resin, amino resin, furan resin, unsaturated polyesterresin, diallyl phthalate resin, allyl resin, alkyd resin, epoxy resin,thermosetting polyamidoimide resin, thermosetting polyimide resin andsilicone resin. The amorphous resin powder may be spherical or flat andhave a mean diameter of 1 μm or less. In addition, flat amorphous resinpowder may have a thickness of 1 μm or less and a flat shape in whichthe length of one side of a square, whose area is same as a surface areain a planar of the amorphous resin powder, is 3 μm or less.

In addition, in the case of using a thermosetting resin as the othercomponents, an example of dispersion treatment with the amorphous resinis polymerization of the amorphous resin and the thermosetting resin.

Moreover, another example of dispersion treatment of the amorphous resinand the other components is a method in which the other components arefilled into pores of a porous body formed by the amorphous resin. Aplurality of the other components may be filled into pores of aplurality of the porous bodies and included in the friction material. Atthis time, sheets of the porous body may be used, and a plurality of theporous body sheets may be laminated. In addition, different othercomponents may be filled into at least two of the plurality of porousbodies.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and further objects, features and advantages of theinvention will become apparent from the following description of exampleembodiments with reference to the accompanying drawings, wherein likenumerals are used to represent like elements and wherein:

FIGS. 1A and 1B are schematic diagrams showing examples of dispersiontreatment in which other components are coated with an amorphous resinin Specific Example (1);

FIGS. 2A, 2B and 2C are schematic diagrams showing in Specific Example(1) portions where a high friction component and a counterpart materialof a friction material make contact in the case of coating the highfriction material with an amorphous resin in dispersion treatment inwhich other components are coated with the amorphous resin; and

FIGS. 3A, 3B and 3C are schematic diagrams showing examples ofdispersion treatment in which other components are filled into pores ofporous body formed by an amorphous resin in Specific Example (4).

DETAILED DESCRIPTION OF EMBODIMENTS

The friction material of an embodiment of the invention includes anamorphous resin having a chain-like polymer structure, and dispersiontreatment is preliminarily carried out in which the amorphous resin isdispersed with respect to at least one of other components that composethe friction material other than the amorphous resin. In thisembodiment, the friction material includes an amorphous resin having achain-like polymer structure (that may also be simply referred to as anamorphous resin) in a highly dispersed state in other components. In theembodiment, in order to realize high dispersion of the amorphous resinin the friction material, rather than simply mixing the amorphous resinwith other components that compose the friction material, the amorphousresin and at least one of the other components that compose the frictionmaterial are preliminarily subjected to dispersion treatment, and theresulting dispersion treatment product is used to form the frictionmaterial.

The resin having a chain-like polymer structure has so-calledthermoplasticity in which the bound state of repeating units thatcompose the polymer are linear, or in other words, one-dimensional, andis softened and deformed by heat. Thermoplastic resins are categorizedinto crystalline resins and amorphous resins. Crystalline resins have aproperty in which the polymer chains are arranged in an orderly manner.Conversely, amorphous resins are either unable to adopt a crystallineform or even if become crystalline, have extremely low crystallinity.Whether or not a resin is a crystalline resin or amorphous resin can beconfirmed by investigating whether or not the resin exhibits a crystaldiffraction pattern as determined by X-ray diffraction or electron beamdiffraction and the like.

Since amorphous resins having a chain-like polymer structure enable therelative positions of polymers to change comparatively smoothly, theyundergo deformation smoothly when subjected to stress. In a frictionmaterial, the material that supports each raw material that composes thefriction material, namely a material that has spring properties, is aresin. Thus, whether or not a friction material deforms smoothly isdetermined by whether or not the resin is able to smoothly undergodeformation. Since frictional vibration of a friction material isdetermined by whether or not two friction surfaces follow each othersmoothly during generation of shear stress during friction, smoothdeformation of the resin under stress is an important factor thatdetermines the presence or absence and magnitude of frictionalvibration. On the basis of such principles, by using an amorphous resinas a constituent of a friction material, the capability of the frictionmaterial to follow the surface of the counterpart material at the pointof generation of frictional force, namely the spring property of thefriction material, can be improved, thereby making it possible toimprove noise properties and vibration properties of the frictionmaterial.

On the other hand, the use of an amorphous resin as a binder componentresults in the problems described below. Namely, since amorphous resinsare softened by heat, in the case of including a large amount thereof ina friction material in the manner of a binder component, the amorphousresin is melted and softened by frictional heat, thereby lowering thefrictional properties of the friction material. In other words, there isthe risk of the amorphous resin destabilizing the frictional propertiesof the friction material. In addition, since amorphous resins havethermoplasticity, the friction material must be molded at hightemperature and high pressure, thereby reducing moldability andproductivity of the friction material. Moreover, amorphous resins aremore expensive than typical binder components in the form of phenolresins, thereby leading to increased cost of friction materials.

Therefore, in this embodiment of the invention, by preliminarilycarrying out dispersion treatment on an amorphous resin with othercomponents and arranging in a friction material in a highly dispersedstate, in comparison with the case of using the amorphous resin as abinder component, the amount of amorphous resin used can be reducedconsiderably, thereby making it possible to improve noise properties andvibration properties of the friction material through the use of anamorphous resin while inhibiting the occurrence of problems caused byuse of an amorphous resin as described above. Here, other componentsrefer to at least one of component among those components that composethe friction material other than the amorphous resin, and may be any ofa base material component, binder component, filler component or othercomponents to be described later, or two or more thereof. In addition,dispersion treatment refers to treatment that enables dispersibility ofthe amorphous resin and other components to be improved, and may employa method such as (1) treatment in which the other components are coatedwith the amorphous resin, (2) treatment in which a powder of theamorphous resin is dispersion mixed into a thermosetting resin, (3)treatment in which the amorphous resin is polymerized with athermosetting resin, (4) treatment in which the other components arefilled into pores of a porous body formed by the amorphous resin, or anyother arbitrary method as will be described later.

There are no particular limitations on the amorphous resin. However, itis necessary that macroscopic properties of highly linear polymersinclude heat resistance and less variation of the ability to deformunder stress, namely elastic modulus. Consequently, the glass transitiontemperature of the amorphous resin is preferably 150° C. or higher,particularly preferably 200° C. or higher and more preferably 250° C. orhigher. In addition, the material that supports each raw material of thefriction material (material having spring properties) is required tohave a high compression modulus. Consequently, the compression modulusof the amorphous resin is preferably 1 GPa or more, particularlypreferably 2 GPa or more, and more preferably 3 GPa or more.

Specific examples of amorphous resins include at least one selected frompolyimide, polyamidoimide, polycarbonate, polyphenylene ether,polyarylate, polysulfone and polyethersulfone; and polyimide,polyamidoimide, polycarbonate and polyphenylene ether resins are usedpreferably. Polyamidoimide or polyimide resin having a high glasstransition temperature and high compression modulus is used particularlypreferably.

The following provides an explanation of an aromatic polyimide obtainedby polymerization or imidization from an aromatic tetracarboxylic acidcomponent and an aromatic diamine component. Examples of aromatictetracarboxylic acid components include aromatic tetracarboxylic acidssuch as pyromellitic acid, 3,3′,4,4′-biphenyl tetracarboxylic acid,2,3,3′,4′-biphenyl tetracarboxylic acid, 3,3′,4,4′-benzophenonetetracarboxylic acid, bis(3,4-dicarboxyphenyl)ether,bis(3,4-dicarboxyphenyl) thioether, bis(3,4-dicarboxyphenyl) methane or2,2-bis(3,4-dicarboxyphenyl) propane, or dianhydrides of these acids. Aplurality of components can also be used in combination. Examples ofaromatic diamine components include 4,4′-diaminodiphenyl ether,4,4′-diaminadiphenyl thioether, 4,4′-diaminodiphenyl methane,4,4′-diaminobenzophenone and o-, m- or p-phenylenediamine. A pluralityof components may also be used in combination. An example of a specificproduction method consists of polymerizing and imidizing the aromatictetracarboxylic acid component and the aromatic diamine component in anorganic polar solvent at a comparative high temperature to precipitatein the form of a high molecular weight aromatic polyimide resin powder,or polymerizing the aromatic tetracarboxylic acid component and thearomatic diamine component in an organic polar solvent at acomparatively low temperature to form a high molecular weight aromaticpolyamic acid, adding a solvent in which the polyamic acid is insolubleto the polymerization liquid to precipitate an aromatic polyamic acidpowder, and imidizing the powder by heating (imidocyclization ofpolyamic acid by a dehydration reaction of acid-amide bonds) to producean aromatic polyimide resin powder.

Only one amorphous resin may be used alone or two or more may be used incombination. The content of the amorphous resin in the friction materialis preferably 50 vol % or less, particularly preferably 40 vol % or lessand more preferably 30 vol % or less, and preferably 0.001 vol % ormore, particularly preferably 0.01 vol % or more, and more preferably0.1 vol % or more. If the content of the amorphous resin exceeds 50 vol%, there is the risk of the frictional properties, moldability andproductivity of the friction material decreasing. On the other hand, inthe case the content of the amorphous resin is less than 0.001 vol %,the effect of the amorphous resin of improving spring properties of thefriction material is not obtained, thereby resulting in the risk ofbeing unable to adequate improve the noise properties and vibrationproperties of the friction material. Furthermore, in the frictionmaterial of this embodiment, depending on the form of dispersiontreatment that enables a highly dispersed arrangement, the amorphousresin acts as, for example, a binder component, a base materialcomponent, a filler component or as a plurality of these components. Inthis embodiment, even in the case the amorphous resin acts as a bindercomponent, for example, other binder components may also be used.

The base material component is a component that is used to retain theshape and ensure the strength of the friction material while alsoenhancing the friction coefficient thereof, and a conventional basematerial may be used. Specific examples of base material componentsinclude inorganic fiber and organic fiber. Examples of inorganic fiberinclude steel fiber, copper fiber, glass fiber, ceramic fiber, potassiumtitanate fiber, rock wool, silicate fiber, alumina fiber, stainlesssteel fiber, titanium fiber, silica fiber, silica-alumina fiber, boronfiber, magnesia fiber and carbon fiber. Examples of organic fiberinclude at least one of aramid fiber, hemp, cotton, aromatic polyamidefiber, linter pulp, wood pulp, synthetic pulp, polyester-based fiber,polyamide-based fiber, polyimide-based fiber, polyvinyl alcohol modifiedfiber, polyvinyl chloride fiber, polypropylene fiber, polybenzoimidazolefiber, acrylic fiber, phenol fiber and cellulose fiber. Aramid fiber isused particularly preferably from the viewpoints of heat resistance,strength and cost. One of base material component may be used alone, ortwo or more may be used in combination.

The binder component is a component used to bind the base materialcomponent, filler component and other constituents, and a conventionalbinder may be used. Specific examples of binder components includephenol resin, modified phenol resin, urea resin, melamine resin,benzoguanamine resin, amino resins other than these resins, furan resin,unsaturated polyester resin, diallyl phthalate resin, allyl resins otherthan diallyl phthalate resin, alkyd resin, epoxy resin, thermosettingpolyamidoimide resin, thermosetting polyimide resin, silicone resin andother thermosetting resins. Phenol resin and modified phenol resin areparticularly preferable from the viewpoints of heat resistance, cost andproduction ease. One of binder component may be used alone or two ormore may be used in combination.

The filler component, that is a component other than the amorphousresin, base material component and binder component, is used to adjustvarious properties of the friction material, such as wear resistance,heat resistance, friction coefficient, stability or coating strength,and a conventional filler component may be used. Specific examples offiller components include friction modifiers, wear modifiers andlubricants. Specific examples of organic filler components includecashew dust and rubber dust. Specific examples of inorganic fillercomponents include barium sulfate, calcium hydroxide, calcium carbonate,mica, talc and metal powder. Examples of lubricants include graphite andmetal sulfides.

One of filler component may be used alone or two or more may be used incombination. In addition, there are no particular limitations on theform of the filler component, and may be in the form of, for example,spheres, plates or fibers.

In this embodiment, the highly dispersed state of the amorphous resin inthe friction material is realized by preliminarily carrying outdispersion treatment on the amorphous resin and other constituents otherthan the amorphous resin (which may simply be referred to as othercomponents) and forming the friction material.

In addition, the amorphous resin, that is the essential component of theembodiment, acts as a base material component, acts as a bindercomponent or acts as a filler component depending on the form ofdispersion treatment as was previously described. For this reason, thereare cases in which the friction material of this embodiment does notinclude at least one of each component previously indicated as examplesof base material components, binder components and filler components.

The following provides an explanation of the dispersion treatmentcarried out on the amorphous resin and other components using SpecificExamples (1) to (4).

(1) Dispersion Treatment in which Other Components are Coated withAmorphous Resin

The dispersed state of the amorphous resin with respect to the othercomponents can be enhanced by preliminarily coating the othercomponents, typically the base material component and/or fillercomponent, with the amorphous resin. The other components coated withthe amorphous resin (which may be referred to as coated components) maybe only one or two or more, and may be all of the other components,namely all constituents other than the amorphous resin. In the case of aportion of the other components being coated with the amorphous resin,the other components coated with the amorphous resin and the remainingother components are mixed. There are no particular limitations on themethod used to coat other components with the amorphous resin, and amethod may be suitably determined according to the combination of theamorphous resin and other components, the form, size, type and amountadded of the other components, and the type and amount added of theamorphous resin. For example, a coated component 2 may be coated with anamorphous resin 1 in a fluid state (see FIG. 1A), or the coatedcomponent 2 may be coated with the amorphous resin 1 in a non-fluidstate (see FIG. 1B).

A typical wet method is an example of a method used to coat the coatedcomponents with an amorphous resin in a fluid state. Namely, a moltenamorphous resin or a dissolved amorphous resin is adhered to the surfaceof the coated components. For example, an amorphous resin in a fluidstate (melted or dissolved) can be coated or sprayed onto the surface ofthe coated components, or the coated components can be immersed in anamorphous resin in a fluid state followed by mixing and suitably dryingto form a coated film of the amorphous resin on the surface of thecoated components. In the case of immersing the coated components in amolten amorphous resin, carrying out immersion in a vacuum allows theobtaining of a uniform coated state.

In the case of coating an amorphous resin in a fluid state in thismanner, together with being able to form a uniform and stable coatedfilm, coating treatment can be carried out all at once for a largeamount of coated components or for a plurality of coated components,thereby resulting in extremely high productivity. On the other hand, inthe case of using a plurality of coated components, carrying out coatingtreatment for each coated component offers the advantage of being ableto set coating treatment conditions that are suitable for each coatedcomponent. The coated components are preferably uniformly coated with afilm-like amorphous resin over the entire surface thereof. In addition,the amorphous resin may also be adhered to the surface of the coatedcomponents in the form of islands. In the case of coating the amorphousresin using a wet method, the amorphous resin is required to havefluidity that allows it to be melted by heat or dissolved in a solvent.Alternatively, monomer that composes the amorphous resin may be put intoa fluid state, the coated components may be coated with the monomer in afluid state, and the monomer may be polymerized on the surface of thecoated components.

A typical dry method is an example of a method used to coat the coatedcomponents with an amorphous resin in a non-fluid state. Specificexamples of such methods include adhering a powder of the amorphousresin to the coated components having an adhesive coated on the surfacethereof, adhering a powder of a monomer of the amorphous resin to thecoated components having an adhesive coated on the surface thereof andthen polymerizing the monomer on the coated components, introducing aheated coated component into a fluid layer composed only of an amorphousresin powder in a non-fluid state and coating, mutually colliding anamorphous resin powder and a raw material of the other components with aball mill or jet mill to adhere the amorphous resin powder on thesurface of the coated component, and granulating the amorphous resin andthe coated component with a granulating machine such as a disc pelleter.

In the case of coating with an amorphous resin in a non-fluid state inthis manner, an amorphous resin having low solvent solubility or lowmeltability can be used. In other words, a wider range of materials canbe selected for the amorphous resin. In addition, since the amount ofamorphous resin used can be reduced in comparison with a wet method, thecost of the friction material can also be reduced. Moreover, since drymethods do not use a solvent as compared with wet methods, a dissolutionstep, drying step and solvent extraction step are no longer required,which together with simplifying the production process resulting insuperior productivity, also places a smaller burden on the environment.In addition, a dry method also offers the advantage of being able touniformly coat the amorphous resin on the surface of the coatedcomponents. In the case of using a plurality of coated components,coating treatment may be carried out for each component, or may becarried out collectively on a plurality of coated components. The coatedcomponents are preferably uniformly coated with a film-like amorphousresin over the entire surface thereof. In addition, the amorphous resinmay also be adhered to the surface of the coated components in the formof islands.

The other components coated with the amorphous resin preferably includea high friction component in particular. The high friction componentrefers to a type of filler component that acts to increase the frictioncoefficient of the friction material. More specifically, in FIGS. 2A, 2Band 2C, the insides of the circles indicated with single-dot brokenlines indicate portions where a friction material raw material (highfriction component) and a counterpart material (typically a disc rotor)5 make contact, and frictional force is generated at these portions.Frictional force changes and vibrations occur as a result of changingthe conditions of contact within the circles. For this reason, coatingthe high friction component 2′ with the amorphous resin 1 results in astructure such that the friction material raw material (high frictioncomponent) is supported by a spring. Thus, even if the conditions ofcontact (such as surface irregularities in the counterpart material suchas a disc rotor) change, since the spring structure has a cushioningaction, the change in the conditions of contact is alleviated therebymaking it difficult for vibrations to occur. In the embodiment asdescribed above, improvement of noise properties and improvement ofvibration properties of a friction material can be effectively enhancedby an amorphous resin while retaining the frictional properties of thefriction material attributable to the high friction component. Inparticular, by coating only a high friction component with an amorphousresin, noise properties and vibration properties of the frictionmaterial can be improved more effectively while ensuring moldability,cost effectiveness and frictional properties of the friction material.

The high friction component refers to a metal component or oxidecomponent and the like having a Mohs hardness of 4 or more andpreferably 6 or more, specific examples of which include magnesiumoxide, zirconium oxide, aluminum oxide, silicon carbide and zirconiumsilicate. Only one of high friction component may be used alone, or twoor more types may be used in combination. In addition, the high frictioncomponent coated with the amorphous resin may be all high frictioncomponents that compose the friction material or only a portion of thehigh friction components. There are no particular limitations on theshape of the high friction component, and may be in the form of spheresor fibers. In addition, although there are no particular limitations onthe particle diameter of the high friction component, it is preferably0.001 to 500 μm and particularly preferably 0.1 to 100 μm as determinedbased on an equivolume sphere.

There is the risk of the high friction component separating from thesurface of the friction material due to a decrease in the retentionforce thereof on the surface of the friction material caused bydeterioration of the binder component or softening and deterioration ofthe amorphous resin accompanying an increase in temperature of thefriction material. Separation of the high friction component leads to adecrease in frictional force of the friction material, reduces brakingeffectiveness, or in the state in which the separated high frictioncomponent remains on the surface of the friction material, leads touneven wear of the surface of the friction material resulting in poorwear resistance of the friction material due to sliding contact betweenthe friction material and the counterpart material. Therefore, the highfriction component coated with the amorphous resin and subjected todispersion treatment is further compounded with a fibrous component.Compounding with a fibrous component results in the high frictioncomponent being incorporated in the fibrous component, thereby improvingretention force of the high friction component to the friction materialand making it possible to inhibit separation of the high frictioncomponent from the surface of the friction material. As a result,stability of frictional properties of the friction material and wearresistance can be improved.

Examples of fibrous components include those composed of the samematerials as those listed as examples of the base material component,and although there are no particular limitations on the form thereof,fiber diameter and fiber length thereof are selected according to theparticle diameter of the high friction component coated with theamorphous resin that inhibits separation. Normally, fiber diameter ispreferably 0.001 to 2000 μm and particularly preferably 1 to 30 μl, andfiber length is preferably 0.1 μm to 50 mm and particularly preferably 1to 30 mm. In addition, aspect ratio (fiber length/fiber diameter) ispreferably 3 to 1000 and particularly preferably 10 to 200. Aramidfibers are selected particularly preferably from the viewpoints ofadhesion to the amorphous resin that coats the high friction component,heat resistance, strength and cost. One of fibrous component may be usedalone, or two or more may be used in combination.

There are no particular limitations on the method used to compound thefibrous component with the high friction component coated with theamorphous resin, and an example of such a method consists of adheringthe high friction component coated with the amorphous resin to thefibrous component using an adhesive. Examples of adhesives include softsubstances such as starch, latex (rubber) or casein, as well asself-curing and solvent-type resin adhesives. Self-curing resinadhesives are selected particularly preferably from the viewpoint ofadhesive strength. The adhesive is coated onto the fibrous componentfollowed by mixing with the high friction component coated with theamorphous resin, or the adhesive is coated onto the high frictioncomponent coated with the amorphous resin followed by mixing with thefibrous component, thereby compounding the adhesive, high frictioncomponent coated with the amorphous resin, and the fibrous component.

The ratio between the high friction component coated with the amorphousresin and the fibrous component compounded with the high frictioncomponent is set as is suitable. All of the fibrous component used asthe above-mentioned base material component may be compounded with thehigh friction component, or a portion of the fibrous component of thebase material component may be compounded with the high frictioncomponent. The specific ratio between the high friction component coatedwith the amorphous resin and the fibrous component in terms of thevolume ratio of the high friction component itself (before coating withthe amorphous resin) to the fibrous component (high friction component:fibrous component) is preferably 1:1 to 1:100 and particularlypreferably 1:5 to 1:20.

A complex of other components coated with the amorphous resin (includingthe high friction component) or the high friction component coated withthe amorphous resin and the fibrous component may be mixed with othercomponents as necessary followed by molding and curing to form afriction material. More specifically, a complex of other componentscoated with the amorphous resin and/or high friction component coatedwith the amorphous resin and the fibrous component is mixed with othercomponents that composes the friction material using a mixer such as anEirich mixer, universal mixer, Lodige mixer or V-blender. Next, theresulting mixer is hot-press molded with a molding metal mold (at, forexample, 130 to 180° C. and 5 to 100 MPa) to obtain a molded body. Thehot-pressing time during hot-press molding may be set as is suitable.The mixture may be pre-molded with a molding metal mold prior tohot-press molding by a molding metal mold, followed by hot-press moldingof the resulting preliminarily molded body. The resulting molded body isthen cured by further subjecting to heat treatment at 150 to 300° C. Theduration of heat treatment may be set as is suitable. Following heattreatment, the molded body is ground and sized as necessary to obtain afriction material.

(2) Dispersion Treatment in which Powdered Amorphous Resin is DispersionMixed into Thermosetting Resin

In the case of using a thermosetting resin for the binder component, bypreliminarily mixing and dispersing a powder of the amorphous resin intoa thermosetting resin, a highly dispersed state of the amorphous resincan be realized during mixing of the dispersion mixture of thethermosetting resin and the amorphous resin with constituents other thanthe thermosetting resin and the amorphous resin. Here, the thermosettingresin dispersion mixed with the powdered amorphous resin may be a liquidor a powder. In addition, during dispersion mixing of the thermosettingresin and the amorphous resin, the amorphous resin retains a solid stateand does not form a solid solution with the thermosetting resin.

Although there are no particular limitations on the shape or size of theamorphous resin powder, it is preferably in the form of spheres having amean particle diameter of 1 μm or less. In this case, since the fluidityof the dispersion mixed thermosetting resin is not impaired when in amolten state, the amorphous resin enters the gaps between othercomponents when the mixed dispersion of the amorphous resin powder andthe thermosetting resin is mixed with other components. Thus, the springproperties of the friction material are enhanced, thereby making itpossible to improve the noise properties and vibration propertiesthereof. The mean particle diameter of a spherical amorphous resinpowder is particularly preferably 100 μm or less and more preferably 20μm or less to facilitate entry into the gaps between other components.On the other hand, the mean particle diameter is preferably 0.01 μm ormore and particularly preferably 0.1 μm or more to absorb vibrations byallowing the construction of a spring structure that supports each rawmaterial that composes the friction material. In addition, the sphericalpowder preferably has high roundness. Here, the mean particle diameterof the amorphous resin powder refers to that of primary particles, andcan be measured by image analysis using an electron microscope or lightmicroscope, or by laser diffraction or sieve analysis.

On the other hand, in the case the amorphous resin powder has a flatshape, since the contact surface area with other components per unitweight is larger than that of spherical particles, the amount ofamorphous resin used can be reduced. Here, in contrast to the lengths inthe x, y and z directions being nearly equal in the case of sphericalparticles, a flat shape refers to a length m in the x, y or z directionhaving the shortest length being ½ or less, and preferably ⅓ or less,relative to the length in at least one of the other directions. Thelength m in a flat shape is taken to be the thickness, while thedirections defined by the remaining two directions are taken to beplanar directions.

An example of a flat shape is a plate, and specifically, preferably aflat shape in which the thickness is 1 μm or less and the length of oneside of a square, whose area is same as the surface area in the planardirection, is 3 μm or less, particularly preferably a flat shape inwhich the thickness is 0.6 μm or less and the length of one side of thesquare as described above is 2 μm or less, and more preferably a flatshape in which the thickness is 0.4 μm or less and the length of oneside of the square as described above is 1.5 μm or less. On the otherhand, in order to construct a spring structure that supports each rawmaterial that composes the friction material, a flat amorphous resinpowder preferably has a thickness of 0.01 μm or more and particularlypreferably 0.1 μm or more, while the length of one side of the square asdescribed above is preferably 0.03 μm or more and particularlypreferably 0.3 μm or more. In addition, the value obtained by dividingthe length of one side of the square as described above by the thicknessis preferably 3 or more, particularly preferably 4 or more and morepreferably 5 or more.

A mixture of spherical shapes and flat shapes is preferably used for theamorphous resin powder from the viewpoints of ensuring fluidity of thethermosetting resin and ensuring a contact surface area for theamorphous resin with other components. The mixing ratio of spherical andflat shapes at this time may be set as is suitable.

There are no particular limitations on the thermosetting resin providedit can be used as a binder component of a friction material, andexamples include those listed as examples of the binder componentspreviously described. Phenol resin and modified phenol resin are usedparticularly preferably from the viewpoints of strength, heat resistanceand cost. The amorphous resin and thermosetting resin that undergopreliminary mixing and dispersion may respectively be the entire amountsthereof that compose the friction material, or only a portion of eachcomponent may be subjected to the above-mentioned dispersion mixingtreatment, while the remainder may be added during subsequent mixingtreatment with other components. Any arbitrary dispersion mixing methodmay be employed for dispersion mixing the amorphous resin powder and thethermosetting resin, and specific examples of such methods includeintroducing a fine amorphous resin powder into a melted thermosettingresin (such as phenol resin) followed by dispersion, dispersing thethermosetting resin (such as phenol resin) and the amorphous resinpowder in a solvent, and adding the amorphous resin duringpolymerization of the thermosetting resin (such as phenol resin). Inparticular, the method in which a fine amorphous resin powder isintroduced into a melted phenol resin followed by dispersion allowsmixing to be carried out without melting or dissolving the amorphousresin.

The dispersion mixture of the amorphous resin and the thermosettingresin is then mixed with other components as necessary in the samemanner as other components coated with the amorphous resin of (1) above,followed by molding and heat treatment, and further carrying out heattreatment, curing and grinding and sizing as necessary to obtain afriction material.

(3) Dispersion Treatment in which Thermosetting Resin and AmorphousResin are Polymerized

In the case of using a thermosetting resin as a binder component, thethermosetting resin and the amorphous resin can be dispersed at themolecular level by preliminarily polymerizing the thermosetting resinand the amorphous resin. Thus, a highly dispersed amorphous resin can berealized when mixing other constituents other than the thermosettingresin and the amorphous resin. As a result, the amount of amorphousresin used can be reduced, and noise properties and vibration propertiesof the friction material can be effectively improved while suppressingincreases in costs and improving moldability.

There are no particular limitations on the form of the polymer of thethermosetting resin and amorphous resin, examples of which include aform that has the basic backbone of the thermosetting resin as the mainchain backbone thereof and in which constituent units of the amorphousresin are bound to side chains in the form of pendants, a form that hasthe basic backbone of the amorphous resin as the main chain backbonethereof and in which constituent units of the thermosetting resin arebound to side chains in the form of pendants, as well as blockcopolymers, random copolymers and alternating copolymers.

Although there are no particular limitations on the polymerizationmethod, since the temperature at which the amorphous resin enters afluid state and the temperature at which the thermosetting resin entersa fluid state have a high tendency to differ considerably, a method ispreferably used by which a monomer or oligomer of the thermosettingresin is polymerized in the presence of the amorphous resin. An exampleof a specific method is described to follow. Namely, in the case of amethod for polymerizing the amorphous resin with the thermosettingresin, graft polymerization is preferable in order to bring out theproperties of the amorphous resin while taking advantage of theproperties of the thermosetting resin. Graft polymerization allows theobtaining of a polymer that incorporates the thermosetting resin for thebasic backbone the amorphous resin as side chains by first activatingthe thermosetting resin by irradiating the thermosetting resin prior tocuring (in the form of a monomer, oligomer or polymer) with shortwavelength visible light such as ultraviolet light or high-energyparticles (such as an electron beam), and then allowing the amorphousresin to react therewith while in the activated state.

The polymerization ratio of the amorphous resin and the thermosettingresin is such that the ratio of the amorphous resin to the entire resinin terms of the constituent units (monomers) of each resin is preferably20 to 80%. The amorphous resin and thermosetting resin that undergopreliminary polymerization are each not required to be the entireamounts thereof that compose the friction material, but rather only aportion of each component used may be polymerized.

A polymer of the amorphous resin and the thermosetting resin are mixedwith other components as necessary in the same manner as othercomponents coated with the amorphous resin in (1) above, followed bymolding and heat treatment, and further carrying out heat treatment,curing and grinding and sizing as necessary to obtain a frictionmaterial.

(4) Dispersion Treatment in which Other Components are Filled into Poresof a Porous Body Formed from Amorphous Resin

A highly dispersed arrangement of the amorphous resin in a frictionmaterial can be realized by forming a porous body with an amorphousresin and filling other components into pores of the porous body. Inthis embodiment, a highly dispersed arrangement of the amorphous resinthat forms the walls of the porous body is realized with respect toother components filled into each of the pores of the porous body. Inaddition, as a result of the amorphous resin that forms the porous bodybeing present continuously in all three dimensional directions in thefriction material, the spring properties of the friction material areimproved and the noise properties and friction properties of thefriction material are further enhanced. In addition, together with othercomponents being retained within the porous body, since the strength andshape of the friction material is ensured by the porous body, in thisembodiment, the amorphous resin that composes the porous body acts as abase material component of the friction material. For this reason, inthis embodiment, the amount of a fibrous component such as inorganicfiber or organic fiber, which is conventionally used as base materialcomponent that has functions such as retaining the shape of ensuring thestrength of the friction material, can be reduced, or the use of afibrous component is not required. In addition, the amount of bindercomponent that binds the components that compose the friction materialcan also be reduced.

Many fibrous components that act as base material components areexpensive, and there are concerns regarding their use in terms of theenvironment as well. Moreover, in addition to destabilization offriction wear properties of the friction material caused by fibrouscomponents, there is also concern over these components having adetrimental effect on noise properties and vibration properties. Inparticular, organic fibers undergo strength deterioration and thermaldecomposition when exposed to high temperatures attributable tofrictional heat during use, resulting in a decrease in incorporationability, which is one of the causes of decreased friction materialdurability. Namely, although fibrous components incorporate constituentssuch as the filler component due to the ability of the fibers to becomeintertwined with each other, if strength deteriorates or the fibersdecompose due to generation of heat during friction, this intertwiningeffect decreases. Consequently, the friction material is damaged ordecreases in strength, thereby resulting in the risk of the frictionmaterial being no longer able to maintain stable performance over a longperiod of time. For this reason, although it is desirable to reduce theamount of fibrous component used, it is difficult to make such areduction from the viewpoints of retaining the shape and strength of thefriction material.

In contrast, in the case of using a base material component in the formof a porous body formed by using an amorphous resin, since otherfriction material raw materials are retained in the gaps of the porousbody as previously described, the effect is obtained by which fibrouscomponents (reinforcing fibers) are either unnecessary or the amount atwhich they are included can be reduced. In addition, since otherfriction material raw materials are retained in individual hole units,the amount of binder component can also be reduced. In addition, sincethe porous body forms a three-dimensional network, there is the effectof the amorphous resin being present throughout the friction material inthe form of a raw material-retaining spring structure. As a result, theamounts used of the fibrous component, binder component and othercomponents such as a filler component can be reduced overall, therebymaking it possible to solve the above-mentioned problems. Thus, byforming a porous body with an amorphous resin and filling othercomponents into pores of the porous body, together with improving noiseproperties and vibration properties of the friction material aspreviously described, moldability and cost effectiveness can also beimproved. Moreover, problems such as destabilization of friction wearproperties attributable to reducing the amount of fibrous component usedas previously described and cost increases can also be solved.Furthermore, pore diameter of the porous body and void diameter of thefriction material can be measured with, for example, a mercuryporosimeter.

Although there are no particular limitations on the specific structureof the porous body formed from the amorphous resin, the porosity ispreferably 30 to 95% and particularly preferably 40 to 90% from theviewpoints of heat resistance and inhibiting noise by spring effects. Inaddition, the mean pore diameter of the porous body is preferably 50 to3000 μm and particularly preferably 100 to 1000 μm from the viewpointsof inhibiting noise by support spring effects and permeability of rawmaterials. In addition, the pores are required to be continuous to allowother components to be filled into the pores.

Any arbitrary technology may be used as the method for forming theporous body with the amorphous resin. For example, the porous body maybe formed by mixing the amorphous resin with a foaming agent, melting ata high temperature and then cooling, or by dissolving the amorphousresin with a solvent and then rapidly depressurizing to evaporate offthe solvent.

Alternatively, a method may be employed in which the amorphous resin ismolded by melting or dissolving with a solvent and then injecting into amold having a honeycomb structure and the like, or the amorphous resinmay be produced in the form of a large number of cylinders, and thesemay be mutually adhered to form a honeycomb structure.

Other components filled into the porous body normally consist ofessential components in the form of the binder component and the fillercomponent, and is preferably a raw material mixture that does notinclude a base material component such as the above-mentioned inorganicfibers or organic fibers. There are no particular limitations on thespecific composition of the raw material mixture, and may be suitablyselected. Normally, the binder component is preferably included at 5 to60 vol % and the filler component is preferably included 0.1 to 90 vol%. Furthermore, in the specific examples, the above-mentioned inorganicfibers and organic fibers or other conventional base material componentsas well as amorphous resin may be included in the components filled intothe porous body. There are no particular limitations on the method usedto fill other components (raw material mixture) into the porous body,and the raw material mixture may be pressed into the porous body usingconventional methods. Specific examples of such methods includedispersing the raw material mixture in a liquid to obtain a slurryfollowed by filling the slurry by pressing into the porous body, orplacing the raw material mixture on the porous body followed by applyingvibrations to fill the raw material mixture into the pores thereof.

There may be one or two or more of the porous body formed from theamorphous resin that composes the friction material. For example, in thecase of using only one porous body, a porous body 3 having the sameexternal shape as the friction material to be produced may be used asshown in FIG. 3A, and other components may be filled into the porousbody 3 to obtain a preliminary molded body of the friction material.Alternatively, two or more porous bodies may be used as in FIG. 3B andFIG. 3C. In this case, a porous body 3 having a smaller bulky form thanthe friction material to be produced may be used (see FIG. 3B), and aplurality of the porous bodies filled with other components may beadhered followed by molding to obtain a preliminary molded body of thefriction material. Alternatively, a sheet of the porous body 3 that isthinner than the friction material to be produced may be used (see FIG.3C), and the porous bodies filled with other components may be laminatedto obtain a preliminary molded body followed by molding. Here, a bulkyform refers to spheres, blocks or chips and the like. Furthermore, FIGS.3A, 3B and 3C show a backing metal 4 that composes a friction membertogether with a friction material of the specific examples. The shape ofthe backing metal 4 is not limited to that in FIGS. 3A, 3B and 3C.

In the case of using a porous body having the same shape as the frictionmaterial to be produced, there are advantages such as uniformly highstrength and eliminating the need for treatment for adhering a pluralityof porous bodies since the porous body is continuous with the frictionmaterial. On the other hand, due to the large size of the porous body,it is difficult to fill a mixture of other components into the pores ofthe porous body.

In contrast, in the case of using a plurality of porous bodies, sincethe porous body can be reduced in size and thickness, filling of amixture of other components therein is both easy and uniform. Moreover,by arranging each porous body in the friction material while changingthe composition of other components filled into each porous body or thestructure of the porous body and the like, an anisotropic frictionmaterial can be obtained that has different frictional properties andfriction wear properties in the direction of the friction surface andthe direction of thickness. For example, uneven wear of the frictionsurface can be inhibited by arranging a material having superior wearresistance in a portion that forms a friction surface susceptible touneven wear, or by arranging a porous body filled with a mixture ofother components having a high content of graphite or sulfide havingsuperior lubricity to impart high friction wear. Alternatively, a porousbody filled with a mixture of other components having a high content ofa raw material that imparts flexibility in the form of an organic fillermay be arranged in a portion that becomes a new friction surface, whichis exposed on the surface of the friction material as a result of wearof the initial friction surface, thereby imparting high springproperties. In this case, even if the thickness of the friction materialdecreases, favorable noise properties and vibration properties can bemaintained. In addition, by arbitrarily designing the elastic modulus ofthe friction material in the direction of thickness by changing theporosity, pore diameter and components in the direction of thickness ofthe friction material, the design is able to demonstrate optimal springproperties even if the friction material becomes worn.

There are no particular limitations on the method used to produce aporous body having a smaller bulky form than the friction material to beproduced, and a method similar to that used for the porous bodydescribed above may be employed to obtain a desired shape and size. Theporous body may also be crushed prior to use. The size and shape of aplurality of bulky porous bodies that compose the friction material maybe mutually different. Although there are no particular limitations onthe size of a bulky porous body, normally the diameter is preferably 1to 30 mm and particularly preferably 3 to 10 mm as determined based onan equivolume sphere from the viewpoints of thickness of the frictionmaterial, filling properties of other components that compose thefriction material, and interlayer strength. A bulky porous body filledwith a mixture of other components may be, for example, further mixedwith the mixture of filled components to prepare a secondary mixture,and this secondary mixture may be molded as a preliminary molded body ofthe friction material.

In addition, there are no particular limitations on the method used toproduce a porous body sheet, and a method similar to that used for theporous body described above may be used to obtain a desired shape andsize. Although there are no particular limitations on the thickness ofthe porous body sheet, normally the thickness is preferably 0.2 to 50 mmand particularly preferably 3 to 10 mm from the viewpoints of thethickness of the friction material, filling properties of othercomponents that compose the friction material, and interlayer strength.An adhesive such as a thermosetting resin may be used between poroussheets filled with a mixture of other components as necessary, followedby joining the sheets and molding in the form of a preliminary moldedbody of the friction material.

Production of Friction Material EXAMPLE 1

A high friction component (zircon: ZrSiO₄) and an amorphous resin(polyamidoimide: PAI) were charged into a kneader heated to 250° C. at avolume ratio of ZrSiO₄/PAI of 8/2 followed by adequately kneading bothcomponents to obtain a mixture of zircon and PAI. Next, this mixture wascrushed to a prescribed diameter with a crusher using a rotary vane toobtain zircon coated with PAI (ZrSiO₄/PAI coating). Each of the rawmaterials shown in Table 1 (blending ratio: vol %) was mixed touniformity for 5 minutes using a vertical mixer to obtain a frictionmaterial raw material mixture. Hot-press molding was then carried out bycharging the friction material raw material mixture into a metal moldheated to 150° C. followed by heating for 10 minutes at 200 kg/cm² (19.6MPa). Subsequently, curing was carried out for 2 hours at 200° C. toobtain a friction material,

TABLE 1 Comparative Comparative Components (vol %) Example 1 Example 1Example 2 Fibrous Aramid fiber  5  5 5 component Copper fiber 10 10 10Glass fiber 10 10 10 Filler Graphite  5  5 5 component ZrSiO₄/PAI 10(8/2) — — coating ZrSiO₄ —  8 8 (no coating) Mica 10 10 10 Bariumsulfate 30 30 30 Binder PAI — — 2 component Phenol resin 20 22 20 Total100  100  100

COMPARATIVE EXAMPLE 1

Each of the raw materials shown in Table 1 was mixed to uniformity for 5minutes using a vertical mixer to obtain a friction material rawmaterial mixture. The resulting friction material raw material mixturewas then used to produce a friction material in the same manner asExample 1.

COMPARATIVE EXAMPLE 2

Each raw material shown in Table 1 was mixed to uniformity for 5 minutesusing a vertical mixer without preliminarily coating the ZrSiO₄ with PAIto obtain a friction material raw material mixture. The resultingfriction material raw material mixture was then used to produce afriction material in the same manner as Example 1.

<Evaluation of Friction Materials> The friction materials obtained inthe example and comparative examples were measured for the number ofoccurrences of squealing and the sound level of that squealing duringsimulated travel through an urban area (100 cycles of braking at a speedof 40 km/h, deceleration of 0.1 to 1.5 m/s² and temperature of 50 to150° C.). The results are shown in Table 2.

TABLE 2 Comparative Comparative Example 1 Example 1 Example 2 Number ofoccurrences 40 100 80 of squealing Squealing sound Low to High to Highto level medium medium medium

According to Table 2, a comparison of Comparative Example 1 andComparative Example 2 reveals that Comparative Example 2, which includedMI, had fewer occurrences of brake squealing than Comparative Example 1,which did not include PAI, and the sound level of that squealing waslower. Moreover, in Example 1, which used a high friction component(zircon) that was preliminarily coated with an amorphous resin in theform of PAI, the number of occurrences of brake squealing was reduced byhalf and squealing sound level was lower than Comparative Example 2,which included the same components at the same ratios with the exceptionof the zircon not being preliminarily coated with PAI. Namely,preliminary coating of a high friction component with an amorphous resinwas determined to have a considerable effect on inhibiting brakesquealing as compared with the case of simply mixing an amorphous resin.

1. A production method of a friction material, comprising: dispersing anamorphous resin selected from the group consisting of a polyimide, apolyamidoimide, a polycarbonate, a polyphenylene ether, a polyarylate, apolysulfone and a polyester sulfone in at least one component selectedfrom the group consisting of a filler component, a binder component anda base component, wherein the dispersing is carried out in the absenceof one or more of the components, to form coated particles wherein atleast one of the components is coated with the amorphous resin, thenmixing the coated particles with the components to form the frictionmaterial, wherein the friction material comprises 0.001 to 50 vol % ofthe amorphous resin.
 2. The production method of a friction materialaccording to claim 1, wherein at least two of the components are coatedwith the amorphous resin in the dispersing.
 3. The production method ofa friction material according to claim 2, wherein at least two of thecomponents are coated with the amorphous resin in a fluid state in thedispersing.
 4. The production method of a friction material according toclaim 2, wherein at least two of the components are coated with theamorphous resin in a non-fluid state in the dispersing.
 5. Theproduction method of a friction material according to claim 2, whereinall of the components that constitute the friction material, other thanthe amorphous resin, are coated with the amorphous resin in thedispersion treatment.
 6. The production method of a friction materialaccording to claim 1, wherein the at least one component is athermosetting resin, and the amorphous resin and the thermosetting resinare polymerized in the dispersing.
 7. The production method of afriction material according to claim 1, wherein the at least onecomponent is filled into pores of a porous body formed from theamorphous resin in the dispersing.
 8. The production method of afriction material according to claim 2, wherein the at least onecomponent in which the amorphous resin is dispersed in the dispersing isa high friction component and the high friction component is coated withthe amorphous resin in the dispersing.
 9. The production method of afriction material according to claim 8, wherein the high frictioncomponent has a Mohs hardness of 6 or more.
 10. The production method ofa friction material according to claim 8, further comprising:compounding the high friction component coated with the amorphous resinwith a fibrous component.
 11. The production method of a frictionmaterial according to claim 7, further comprising: forming the frictionmaterial from a plurality of porous bodies filled with at the least onecomponent.
 12. The production method of a friction material according toclaim 11, wherein the porous bodies are sheets, and a plurality ofporous body sheets filled with the at least one component are laminated.13. The production method of a friction material according to claim 11,wherein different components are filled into at least two of theplurality of porous bodies in the dispersing.
 14. The production methodof a friction material according to claim 1, wherein the at least onecomponent is a thermosetting resin, and a powder of the amorphous resinis dispersion mixed with the thermosetting resin in the dispersing. 15.The production method of a friction material according to claim 14,wherein the thermosetting resin is at least one selected from the groupconsisting of a phenolic resin, a modified phenol resin, a urea resin, amelamine resin, a benzoguanamine resin, an amino resin, a furan resin,an unsaturated polyester resin, a diallyl phthalate resin, an allylresin, an alkyd resin, an epoxy resin, a thermosetting polyamidoimideresin, a thermosetting polyimide resin and a silicone resin.
 16. Theproduction method of a friction material according to claim 14, whereinthe powder of the amorphous resin is a spherical powder that has a meanparticle diameter of 1 μm or less.
 17. The production method of afriction material according to claim 14, wherein the powder of theamorphous resin has a flat shape.
 18. The production method of afriction material according to claim 17, wherein the powder of theamorphous resin has a flat shape that has a thickness of 1 μm or lessand a length of one side of a square, whose area is same as a surfacearea in a planar direction of the powder of the amorphous resin, is 3 μmor less.